Systems and methods for plastic-free button-lock tube containers

ABSTRACT

A plastic-free, button-lock tube container comprising: a first tube assembly having a cylindrical body with an open end, a closed end, and a first opening formed in the wall of the body; a second tube assembly having a cylindrical body configured to telescopically interface with the first tube assembly along a portion of its length and having a second opening formed therein; a locking apparatus including a manually actuatable button and an elastically deformable structure mechanically coupled to the manually actuatable button such that, when the button-lock tube container is in a closed state, the elastically deformable structure applies an outward radial force to the manually actuatable button such that it projects through the first and second openings and prevents sliding motion between the first and second tube assemblies; wherein the first tube assembly, the second tube assembly, and the locking apparatus are plastic-free components.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/332,821, entitled SYSTEMS AND METHODS FOR PLASTIC-FREE BUTTON-LOCK TUBE CONTAINERS, which was filed on Apr. 20, 2022, the entire contents of which are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates, generally, to the manufacture of plastic-free, fiber-based packaging and containers. More particularly, the present invention relates to button-lock, child-resistant containers in which all components of the resulting assembly are plastic-free.

BACKGROUND

Pollution caused by plastic containers and packaging materials is epidemic, scarring the global landscape and threatening delicate ecosystems and the life forms that inhabit them. Single use containers migrate along waterways to the oceans in the form of Styrofoam and expanded polystyrene (EPS) packaging, to-go containers, bottles, thin film bags and photo-degraded plastic pellets, and the like.

Fiber-based packaging products, on the other hand, are biodegradable, compostable and, unlike plastics, do not migrate into the ocean. While it would be desirable to manufacture all packaging materials and containers using such materials, there remain some container categories that still rely on the use of at least some plastic components.

Child-resistant containers, for example, are based on components that interact in such a way that it is intractable for a child to open, thereby protecting the child from accessing the container's contents (e.g., prescription medicine, cannabis cigarettes, and the like). Such child-proof or child-resistant components are often designed with one or more buttons, caps, and elastically-deformable structures whose characteristics have traditionally necessitated the use of plastic materials.

Systems and methods are therefore needed that overcome these and other limitations of prior art child-resistant containers.

SUMMARY

In accordance with various aspects of the present invention, a plastic-free, button-lock tube container is described, including a child-resistant container design in which the button and elastically deformable subassembly are, unlike the prior art, entirely manufactured from fiber-based materials. In one embodiment, the container includes a first tube assembly having a cylindrical body with an open end, a closed end, and a first opening formed in the wall of the body; a second tube assembly having a cylindrical body configured to telescopically interface with the first tube assembly along a portion of its length and having a second opening formed therein; and a locking apparatus including a manually actuatable button and an elastically deformable structure mechanically coupled to the manually actuatable button such that, when the button-lock tube container is in a closed state, the elastically deformable structure applies an outward radial force to the manually actuatable button such that it projects through the first and second openings and prevents sliding motion between the first and second tube assemblies.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The present invention will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements, and:

FIG. 1A illustrates a button-lock container in its closed state;

FIG. 1B illustrates a button-lock container where the button 131 is depressed so that it no longer interferes with the movement of the second tube assembly 110;

FIG. 1C illustrates a button-lock container where the first tube assembly 120 and second tube assembly 110 are pulled apart axially;

FIG. 2 illustrates a button and elastically deformable component in accordance with various embodiments; and

FIG. 3 depicts a disassembled button-lock container in accordance with an example embodiment.

DETAILED DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS

The present invention generally relates to various designs for plastic-free, button-lock tube containers. In particular, the present invention relates to a child-resistant container design in which the button and elastically deformable subassembly are, unlike the prior art, entirely manufactured from fiber-based materials. As a preliminary matter, it will be understood that the following detailed description is merely exemplary in nature and is not intended to limit the inventions or the application and uses of the inventions described herein. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description. In the interest of brevity, conventional techniques and components related to fiber-based materials, paper-processing processes, cannabis products, and the like need not be described herein.

Referring now to FIGS. 1A-1C, a plastic-free, button-lock tube container 100 in accordance with the present invention generally includes a first tube assembly 120 and a second tube assembly 110 that telescopically fit together (i.e., telescopically and slideably interface in some manner along at least a portion of the length of first tube assembly 120) to form a child-resistant enclosure. The first tube assembly 120 includes a generally cylindrical body having an open end, a closed end, and an opening 122 formed in the wall of the body. The first tube assembly 120 further includes a locking apparatus comprising a manually actuatable button 131 (which projects through the opening 122 in the body) and an elastically deformable structure (e.g., 132) mechanically coupled to the button 131 such that the button itself springs back into place after being pressed radially with respect to the central axis of body 121.

The second tube assembly 110 also includes a generally cylindrical body 111 having an open end, a closed end, and an opening 112 formed in the wall of the body 111. The inner diameter of the second tube 110 is greater than or equal to at least a portion of the outer diameter of the first tube assembly 120, such that the pair of tube assemblies (110, 120) can slidably engage and disengage with each other.

With the container in its closed state (FIG. 1A), the button 131 of the first tube assembly 120 projects through the openings in both the first and second tube assemblies (112, 122), thereby preventing the tube assemblies 110 and 120 from disengaging through axial force. To open the container 100, the user must depress the button 131 such that it no longer interferes with movement of the second tube assembly 110 (see FIG. 1B) while at the same time pulling the tube assemblies apart axially (see FIG. 1C). In this way, due to the difficulty in pressing the button while sliding the tube assemblies apart, the container as a whole is child-resistant.

The elastically deformable structure 132 may be a separate component or integral with the button itself (i.e., a spring structure that extends like “wings” from the button). In one embodiment, for example, the elastically deformable structure is a thin insert or collar that is coiled up within the first tube assembly and makes contact with the backside of the button 131 (as shown in FIGS. 1A-1C), thereby keeping the button in place. In some embodiments, the length of the insert is just slightly less than the circumference of the inner surface of the first tube assembly 120, resulting in a “slit” or gap (e.g., a 1.0-0.1 inch gap) between opposing ends of the insert. This configuration assists in the “kitting” (assembly) process.

In another embodiment, as shown in FIG. 2 , the button may be integral with lateral wings (232A, 232B) that extend from the button 131 as shown. In this way, the entire structure may be formed in an arcuate fashion as shown such that it fits within the interior of first tube assembly 120.

The height, thickness, and radius of the respective tubes 110 and 120 may be selected based on the size and type of object intended to be encapsulated by the enclosure. In one embodiment, as shown in FIG. 3 , the container 100 is designed to hold cigarettes (e.g., cannabis cigarettes) and is therefore elongated as depicted in the figure. Similarly, the size of the button and the thickness and “springiness” of the elastically deformable component may be selected based on the desired force required to open the container. It will be appreciated that the embodiments shown in figure are not intended to be limiting with respect to geometrical dimensions, and may not be drawn to scale.

As shown in FIG. 3 , one embodiment of button 131 is a one-piece assembly in which the circular button is “hollow” and is flanked by a shoulder region, wherein the button itself has rounded corners to help it smoothly move through the openings in the tubes. Such a shape is also amenable to fabrication using pulp-based slurries.

That is, the locking mechanism may be fabricated by providing a wire mesh mold in the shape of the button (e.g., a round button as shown in FIGS. 1-3 ), then immersing the mold in a fiber-based slurry. The process continues by drawing a vacuum across the wire mold to cause fiber particles to accumulate at the wire mesh surface. The mold and attached fiber particles are then removed from the slurry, and the structure is dried to yield the button.

The tube assemblies 110 and 120 may be manufactured as one piece (i.e., with their end-caps and shoulder regions “spun” in the way paper products are traditionally manufactured) or formed from one or more subassemblies.

As mentioned briefly above, one of the primary advantages of the present invention is that the container — including the button and elastically deformable structure—are biodegradable, rather than plastic. The plastic-free components described herein be manufactured using a variety of fiber-based mixtures of pulp and water, with added chemical components, if desired, to impart performance characteristics tuned to each particular product application, such as a strength additive (e.g., Hercobond). For additional information regarding such fiber-based systems and methods, see, for example U.S. Pat. Nos. 10,815,622, 10,428,467, 9,988,199, and 9,856,608, the entire contents of which are hereby incorporated by reference.

The system may be described herein in terms of functional and/or logical block components and various processing steps. It should be appreciated that such block components may be realized and implemented by any number of hardware, software, and/or firmware components configured to perform the specified functions.

In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any number of systems, and that the systems described herein are merely exemplary embodiments of the present disclosure. Further, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the present disclosure.

As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations, nor is it intended to be construed as a model that must be literally duplicated.

While the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing various embodiments of the invention, it should be appreciated that the particular embodiments described above are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. To the contrary, various changes may be made in the function and arrangement of elements described without departing from the scope of the invention. 

What is claimed is:
 1. A plastic-free, button-lock tube container comprising: a first tube assembly having a cylindrical body with an open end, a closed end, and a first opening formed in the wall of the body; a second tube assembly having a cylindrical body configured to telescopically interface with the first tube assembly along a portion of its length and having a second opening formed therein; a locking apparatus including a manually actuatable button and an elastically deformable structure mechanically coupled to the manually actuatable button such that, when the button-lock tube container is in a closed state, the elastically deformable structure applies an outward radial force to the manually actuatable button such that it projects through the first and second openings and prevents sliding motion between the first and second tube assemblies; wherein the first tube assembly, the second tube assembly, and the locking apparatus are plastic-free components.
 2. The container of claim 1, wherein the locking apparatus comprises a button portion and a collar portion that is coiled within the first tube assembly and makes contact with a backside surface of the button portion.
 3. The container of claim 2, wherein collar portion has a length that is less than the circumference of the inner surface of the first tube assembly such that a gap of about 1.0 inch to 0.1 inch remains between the two ends of the collar portion when the locking apparatus is inserted within the first tube assembly.
 4. The container of claim 1, wherein the locking apparatus comprises a button portion and integral, laterally extending lateral wings whose total length is greater than half the circumference of the inner surface of the first tube assembly.
 5. The container of claim 4, wherein collar portion has a length that is less than the circumference of the inner surface of the first tube assembly such that a gap of about 1.0 inch to 0.1 inch remains between the two ends of the lateral wings when the locking apparatus is inserted within the first tube assembly.
 6. The container of claim 1, wherein at least a portion of the plastic free components contain a fiber-based mixture including at least one of softwood, bagasse, bamboo, and old corrugated containers.
 7. A method for manufacturing a plastic-free, button-lock tube container comprising: forming, from a plastic-free material, a first tube assembly having a cylindrical body with an open end, a closed end, and a first opening formed in the wall of the body; forming, from a plastic-free material, a second tube assembly having a cylindrical body configured to telescopically interface with the first tube assembly along a portion of its length and having a second opening formed therein; forming a locking apparatus including a manually actuatable button and an elastically deformable structure mechanically coupled to the manually actuatable button such that, when the button-lock tube container is in a closed state, the elastically deformable structure applies an outward radial force to the manually actuatable button such that it projects through the first and second openings and prevents sliding motion between the first and second tube assemblies; wherein forming the locking apparatus comprises: providing a wire mesh mold in the shape of the button; immersing the mold in a fiber-based slurry; drawing a vacuum across the wire mold to cause fiber particles to accumulate at the wire mesh surface; and removing the mold and attached fiber particles from the slurry; and subsequently drying the fiber particles to yield the button.
 8. The method of claim 7, further including introducing a strength additive to the fiber-based slurry.
 9. The method of claim 8, wherein the strength additive is in the range of 1.5%-4.0% by weight.
 10. The method of claim 7, wherein the locking apparatus comprises a button portion and a collar portion that is coiled within the first tube assembly and makes contact with a backside surface of the button portion.
 11. The method of claim 10, wherein collar portion has a length that is less than the circumference of the inner surface of the first tube assembly such that a gap of about 1.0 inch to 0.1 inch remains between the two ends of the collar portion when the locking apparatus is inserted within the first tube assembly.
 12. The method of claim 7, wherein the locking apparatus comprises a button portion and integral, laterally extending lateral wings whose total length is greater than half the circumference of the inner surface of the first tube assembly.
 13. The method of claim 12, wherein collar portion has a length that is less than the circumference of the inner surface of the first tube assembly such that a gap of about 1.0 inch to 0.1 inch remains between the two ends of the lateral wings when the locking apparatus is inserted within the first tube assembly.
 14. The method of claim 7, wherein at least a portion of the plastic free components contain a fiber-based mixture including at least one of softwood, bagasse, bamboo, and old corrugated containers. 